Process for improving the convertibility of convolutely wound web material parent rolls

ABSTRACT

A process for improving the convertability of parent rolls of convolutely wound web materials is disclosed.

FIELD OF THE INVENTION

The present disclosure is directed to improvements in the convertibility of parent rolls of wound web materials. In particular, the present disclosure relates to the use of a parent roll transporter capable of moving large parent rolls of convolutely wound web materials from a first location to a second location and eliminates the deficiencies present by the use of current compressive-type parent roll handling clamp machines.

BACKGROUND OF THE INVENTION

Clamps are normally required to handle paper rolls of widely-varying diameters in both vertical and horizontal orientations. A typical clamp comprises a pair of clamp arms either slidably or pivotally mounted upon a clamp frame and movable with respect to such frame selectively toward and away from each other to engage or release paper rolls of different diameters.

In a simple form of handling large diameter and weight rolls of convolutely wound web materials, it has been the practice to move them from the storage location to the printing machines by means of lift trucks. The lift trucks heretofore used have been provided with horizontally extending forks for engaging and lifting the paper rolls. In this arrangement, the forks are inserted underneath the roll of paper and the roll lifted. This often results in tearing or wrinkling of the paper.

Alternatively, as shown in FIGS. 1-2, an exemplary prior art paper roll handling clamp designated generally as 10 is mounted on a mast 12 at the forward end of a lift truck (not shown). The clamp 10 has a clamp frame 14 which is rotatably mounted by means of a rotator 16 upon a carriage 18 which moves vertically selectively upward or downward on the mast 12. The rotator 16 provides powered rotation of the clamp frame 14 about an axis of rotation 20 extending generally forwardly from the mast 12 and carriage 18 along the longitudinal centerline of the lift truck. Such rotation permits the clamp 10 to handle paper rolls such as 22 and 22 a both in a horizontal orientation or, alternatively, in a vertical orientation as shown in FIG. 2.

The clamp frame 14 mounts respective pairs of transversely-extending, axially-aligned pivot pins 24 and 26 respectively. Pivotally mounted upon the frame 14 by pivot pins 24 is a forwardly-projecting, selectively openable and closable clamp arm 28, while an opposing clamp arm 30 is pivotally mounted on the frame 14 by means of pins 26. Each clamp arm is equipped with a respective paper roll engaging arcuate contact pad 32, 34 defining the forward tip of the respective clamp arm 28, 30. Each contact pad is hingedly connected to the remainder of the clamp arm by a respective hinge 36, 38.

Clamp arm 28 is pivotable angularly with respect to the clamp frame 14 selectively toward and away from the other clamp arm 30 by the selective extension and retraction of a pair of double-acting hydraulic ram assemblies 40 (only one of which is shown in FIG. 2) pivotally connected to the frame 14 at their bases by a common vertically-extending pin 42 having a roller 44 rotatably mounted about a mid-portion thereof. The ram assemblies 40 are connected at their forward ends to the clamp arm 28 by a vertically-extending common pin 46 likewise having a roller 48 rotatably mounted about a mid-portion thereof.

Clamp arm 30 is similarly selectively pivotable angularly with respect to frame 14 by a pair of double-acting hydraulic ram assemblies 50 (only one of which is shown in FIG. 2) pivotally connected at their bases to the frame 14 by a common vertically-extending pin 52 having a roller 54 rotatably mounted about a mid-portion thereof. The forward ends of ram assemblies 50 are connected to the clamp arm 30 by a common vertically-extending pin 56 having a roller 58 rotatably mounted about a mid-portion thereof.

Each of the clamp arms 28, 30 has a respective roll positioner anchor bar 70, 72 affixed thereto, to each of which is affixed a respective end of an elongate flexible strap 64, constructed of a suitable material such as a nylon woven web of the type used for lifting slings. From each of the anchor bars 70, 72, the strap 64 is reeved first about a respective roller 44, 54 on the frame 14 and then around a respective roller 48, 58 on the respective clamp arms 28, 30, crossing transversely between the rollers 48 and 58. The operative part of the strap constituting the roll positioner is the portion extending transversely between the rollers 48 and 58, such rollers 48 and 58 defining the two extremities of the roll positioner and the remaining portions of the strap 64 comprising structure for preventing excessive slack in the strap by selectively taking up and paying out portions of the strap as the clamp arms move toward and away from each other respectively.

In operation, it can be seen from FIG. 2 that each extremity of the roll positioner portion of the strap 64, as defined by the rollers 48 and 58 respectively, moves forwardly with respect to the clamp frame 14 automatically in response to movement of its respective clamp arm toward the other clamp arm, and conversely moves rearwardly in response to movement of its clamp arm away from the other clamp arm. This occurs whether or not the clamp arms move toward or away from each other concurrently.

When a roll of smaller diameter such as roll 22 in FIG. 2 is to be grasped, the portion of the strap 64 between the rollers 48 and 58 moves forwardly toward the position shown in solid lines in FIG. 2 as the clamp arms close toward one another to a point where their contact pads are separated by a distance slightly greater than the diameter of the roll 22. The position of the portion of the strap 64 extending between the rollers 48 and 58 is such that it will abut the rear surface of the paper roll 22 when the contact pads 32 and 36 are in substantially-diametrically-opposed relation for proper gripping of the roll, thereby automatically positioning the clamp arms with respect to the roll.

Conversely, if a larger roll such as that indicated as 22 a in FIG. 2 is to be grasped, the clamp arms 28 and 30 are pivoted away from each other to the positions shown in phantom in FIG. 2, thereby moving the rollers 48 and 58 rearwardly with respect to the clamp frame 14. It will be noted that such movement of the clamp arms 28 and 30 away from each other moves the anchor bars 70 and 72 substantially closer to the pins 42 and 52 and their respective rollers 44 and 54, and also moves the rollers 48 and 58 closer to the rollers 44 and 54 respectively, thereby paying out additional portions of strap 64. Some of the quantity of strap paid out is needed to accommodate the wider separation of pins 48 and 58, but a greater amount of slack in the operative portion of the strap 64 also results, thereby allowing the portion of the strap 64 between the rollers 48 and 58 to bow to a greater degree than in the position of the clamp arms previously discussed. The more rearward position of the operative portion of the strap 64 as shown in phantom in FIG. 2, resulting from the opening of the clamp arms 28 and 30 to handle the larger roll 22 a, is appropriate to permit the contact pads to engage the larger roll in diametrically-opposed relation.

The operative portion of the strap 64 has a loop of material 66 on the rear side thereof through which are stretched a vertically spaced pair of resilient elastomer bands 68 of any suitable type, anchored at each end to the respective anchor bars 70 and 72. The elastomer bands 68, only one of which is shown, bias the flexible operative portion of the strap 64 between the rollers 48 and 58 to a generally concave forwardly-facing configuration in the various clamp arm positions. Anchor bar 70 can be provided with several alternative mounting screw apertures 74 by which the length of the strap 64 may be adjusted.

In the papermaking industry, it is generally known that paper to be converted into a consumer product such as paper towels, bath tissue, facial tissue, and the like is initially manufactured and wound into large rolls. By way of example only, these rolls, commonly known as parent rolls, may be on the order of 10 feet in diameter and 100 inches across and generally comprise a suitable paper wound on a core. In the usual case, a paper converting facility will have on hand a sufficient inventory of parent rolls to be able to meet the expected demand for the paper conversion as the paper product(s) are being manufactured.

However used, the compressive-type clamps, discussed supra, have numerous draw-backs. The most significant of these is the use of a compressive-type clamp for the pick-up and transport of convolutely wound web materials (e.g., a parent roll of paper) is the deformation of the cylindrical surface of the parent roll by the compressive-type clamp.

Because of the soft nature of the paper used to manufacture paper towels, bath tissue, facial tissue, and the like, it is common for parent rolls to become out-of-round. Not only the soft nature of the paper, but also the physical size of the parent rolls, the length of time during which the parent rolls are stored, and the fact that roll grabbers using these compressive-type clamps used to transport parent rolls grab them about their circumference can contribute to this problem. As a result, by the time many parent rolls are placed on an unwind stand they have changed from the desired cylindrical shape to an out-of-round shape. An exemplary un-compressed parent roll is shown in FIG. 2A. An exemplary compressed parent roll due to contacting engagement of the parent roll with an exemplary prior art compressive-type clamps is shown in FIG. 2B.

Because the weight of a parent roll is typically quite substantial, the compressive-type clamps must necessarily exert a significant amount of force upon the surface of the roll in order to maintain control of the roll during movement of the roll from one location to another. This artifact of surface deformation is particularly exacerbated upon convolutely wound parent rolls of tissue and towel substrates such as bath tissue and paper toweling. Since these products tend to be of low basis weight and can have decorative surface architectures, any compressive force applied to the surface thereof tends to distort the shape of the parent roll. An out-of-round parent roll may not be perfectly oblong or elliptical but, rather, they may assume a somewhat flattened condition resembling a flat tire, or an oblong or egg-shape, or any other out-of-round shape depending upon the amount of force required to securely hold the parent roll.

Even only slightly out-of-round parent rolls present considerable problems. In an ideal case with a perfectly round parent roll, the feed rate of a web material coming off of a rotating parent roll can be equal to the driving speed of a surface driven parent roll. However, with an out-of-round parent roll the feed rate can likely vary from the driving speed of a surface drive parent roll depending upon the radius at the web takeoff point at any moment in time. If the rotational speed remains substantially constant, the feed rate of a web material coming off of an out-of-round parent roll will necessarily vary during any particular rotational cycle depending upon the degree to which the parent roll is out-of-round. In practice, however, parent rolls are surface driven which means that if the radius at the drive point changes, the rotational speed can also change generally causing variations in the feed rate. Since the paper converting equipment downstream of the unwind stand is generally designed to operate based upon the assumption that the feed rate of a web material coming off of a rotating parent roll will always be equal to the driving speed of the parent roll, there are problems created by web tension spikes and slackening.

Additionally, it is believed that an out-of-round parent roll produces finally wound consumer products having inconsistent desired physical characteristics. Without desiring to be bound by theory, it is believed that a compressive-type clamp used for the conventional pick-up of a parent roll of wound web material effectively removes any caliper that may have been built into the product being produced for the parent roll. It is believed that this lost caliper cannot be recovered to any large degree due to the early stage of the life of the web material that is being so compressed. This lost and unrecoverable caliper can have a deleterious effect on the finally converted web material because the desired target values of the chosen parameters will be out of range even before the converting process has begun. Net—this clearly undesirable effect on the end product can be noticed by an end user of the product.

Regardless of the amount of pressure exerted by the compressive-type clamps on the parent roll, at least one point in the rotation of the parent roll exists where the relationship between the web take off point radius and the parent roll drive point radius that results in the minimum feed rate of paper to the line. At this point, the web tension can spike since the feed rate of the web material is at a minimum and less than what is expected by the paper converting equipment downstream of the unwind stand. Similarly, there can exist at least one point in the rotation of the parent roll where the relationship between the web take off point radius and the parent roll drive point radius results in the maximum feed rate of paper to the line. At this point, the web tension can slacken since the feed rate of the web material can be at a maximum and more than what is expected by the paper converting equipment downstream of the unwind stand. Since neither condition is conducive to efficiently operating paper converting equipment for manufacturing paper products such as paper towels, bath tissue and the like, and a spike in the web tension can even result in a break in the web material requiring a paper converting line to be shut down, there clearly is a need to overcome this problem.

In particular, the fact that out-of-round parent rolls create variable web feed rates and corresponding web tension spikes and web tension slackening has required that the unwind stand and associated paper converting equipment operating downstream thereof be run at a slower speed in many instances thereby creating an adverse impact on manufacturing efficiency.

Additionally, typical compressive-type clamp arms normally have a concave contact pad on the forwardly-extending tip thereof for engaging the cylindrical surface of the roll. For proper engagement, to ensure that the roll does not slip from the grasp of the clamp, it is important that the two contact pads engage the roll in substantially diametrically-opposed positions. This requires the lift truck operator to adjust the positions of the clamp arms relative to the roll prior to engagement such that the contact pads will neither under reach nor overreach the roll but rather will engage it in such diametrically-opposed positions. Because lift truck operators are normally hampered by visibility limitations imposed by the lift truck mast and clamp frame, it is often quite difficult for the operator to see the exact relationship between the contact pads and the roll. Particularly when rolls of different diameters are being handled, the operator is often forced to estimate roughly the proper positions of the contact pads with respect to a particular roll, resulting in inaccurate positioning of the contact pads and insecure engagement of the roll.

Thus, there is a long-felt need to provide a better manner for the handling of parent rolls that eliminates the problems experienced and observed by manufactures using current roll-handling technology such as the aforementioned typical compressive-type clamp arms. It would be beneficial if the long-felt need was resolved by equipment that assists in maintaining the desired cylindrical parent roll shape. It would also be beneficial if the new parent roll handling equipment also maintained better control of the parent roll during movement. Further, it would be beneficial if the new parent roll handling equipment provided greater flexibility in the options required by paper product manufacturing operations by providing a more direct interface with the dry end of parent roll production, the ability to manipulate parent roll orientation for parent storage, as well as the ability to manipulate parent roll orientation for insertion of the parent roll into a converting process.

SUMMARY OF THE DISCLOSURE

The present disclosure provides for a process for improving the convertability of parent rolls of convolutely wound web materials. The process comprising the steps of: a) producing a web material with a paper machine; b) forming a parent roll of the web material by convolutely winding the web material about a core to form the parent roll; c) operatively engaging an end effector having a first core plug and a second core plug operatively connected thereto with the core of the parent roll, the first core plug engaging a first end of the core and the second core plug operatively engaging a second end of the core, the second end being distal from the first end, the end effector being operatively connected to a motivator to form a parent roll transport device; d) transporting the parent roll with the parent roll transport device to a parent roll converting apparatus; e) operatively disposing the parent roll in the converting apparatus; and, f) converting the parent roll.

Alternatively, the present disclosure provides for a process for improving the convertability of parent rolls of convolutely wound web materials. The process comprises the steps of: a) producing a web material with a paper machine; b) forming a parent roll of the web material by convolutely winding the web material about a core to form the parent roll; c) operatively engaging an end effector having a first core plug, a second core plug, and a platform disposed about the second core plug operatively connected thereto with the core of the parent roll, the first core plug engaging a first end of the core, the second core plug operatively engaging a second end of the core, and a first end of the parent roll being engaged with a surface of the platform when the first core plug is engaged with the first end of the core and the second core plug is engaging with the second end of the core, the second end being distal from the first end, the end effector being operatively connected to a motivator to form a parent roll transport device; d) transporting the parent roll with the parent roll transport device to a parent roll converting apparatus; e) operatively disposing the parent roll in the converting apparatus; and, f) converting the parent roll.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an exemplary prior art paper roll clamp having a pair of pivoted clamp arms and an automatically-adjustable roll positioner, such clamp being mounted on a lift truck mast and in a rotational position for handling vertically-oriented paper rolls;

FIG. 2 is a partially-sectional top view of the exemplary prior art paper roll clamp of FIG. 1 illustrating the clamp arms and roll positioner at different positions for handling paper rolls of different diameters;

FIG. 2A is a photograph of an exemplary prior art paper roll clamp having a pair of pivoted clamp arms mounted on a lift truck mast prior to contacting engagement with a parent roll of a typical web material used for the production of consumer products such as bath tissue, facial tissue, and/or paper toweling;

FIG. 2B is a photograph of an exemplary prior art paper roll clamp having a pair of pivoted clamp arms mounted on a lift truck mast in contacting engagement with a parent roll of a typical web material used for the production of consumer products such as bath tissue, facial tissue, and/or paper toweling, the photograph showing significant deformation observed in the parent roll due to the compressing engagement of the paper roll clamp with the parent roll;

FIG. 3 is an exemplary sectional view of a papermaking machine suitable for use in making parent rolls of convolutely wound web materials that are suitable for handling by the apparatus of the present disclosure;

FIG. 4 is a perspective view of the exemplary parent roll transporter of the present disclosure showing the motivator and end effector and their relationship to an incoming parent roll of web material to be handled thereby;

FIG. 5 is a perspective view of the exemplary parent roll transporter of FIG. 4 showing the motivator and end effector and their relationship to an incoming parent roll of web material to be handled thereby and the first and second core plugs as they would appear when cooperatively and insertingly engaged with a parent roll disposed upon the platform;

FIG. 6 is a perspective view of the exemplary parent roll transporter of FIG. 4 showing the parent roll disposed upon the platform of the end effector and the relationship of the first and second core plugs relative to the core;

FIG. 7 is a perspective view of the exemplary parent roll transporter of FIG. 4 showing the parent roll disposed upon the platform of the end effector and the initiation of engagement of the first and second core plugs with the core;

FIG. 8 is a perspective view of the exemplary parent roll transporter of FIG. 4 showing the parent roll disposed upon the platform of the end effector and the complete engagement of the first and second core plugs with the core;

FIG. 8A is a perspective view of a parent roll disposed upon a platform that has been disassociated from the end effector;

FIG. 9 is a perspective view of the exemplary parent roll transporter of FIG. 4 showing the parent roll disposed upon the platform of the end effector and the complete engagement of the first and second core plugs with the core where the end effector is rotating the parent roll about the rotational axis of the end effector and changing the orientation of the longitudinal axis of the core of a parent roll;

FIG. 10 is a perspective view of the exemplary parent roll transporter of FIG. 9 showing the parent roll disposed upon the platform of the end effector and the complete engagement of the first and second core plugs with the core here the end effector has rotated the parent roll about the rotational axis of the end effector and changed the orientation of the longitudinal axis of the core of a parent roll;

FIG. 11 is a perspective view of another exemplary parent roll transporter showing a parent roll disposed upon the platform of the end effector where the platform is in the form of a pallet and where the first and second core plugs are in complete engagement with the core;

FIG. 12 is a perspective view of another exemplary parent roll transporter of FIG. 12 showing a parent roll disposed upon the platform of the end effector where the platform is in the form of a pallet and where the first and second core plugs are in complete engagement with the core and the end effector has rotated the parent roll about the rotational axis of the end effector and changed the orientation of the longitudinal axis of the core of a parent roll;

FIG. 13 is a perspective view of a parent roll disposed upon a platform as shown in FIG. 11 that has been disassociated from the end effector;

FIG. 14 is a perspective view of another exemplary parent roll transporter where the first and second core plugs are in complete engagement with a horizontally oriented core taken directly from the reel-up section of a papermaking machine;

FIG. 15 is a perspective view of the exemplary parent roll transporter of FIG. 14 where the first and second core plugs are ready for engagement with a vertically oriented core disposed upon a split conveyor departing from the up-ender;

FIG. 15A is a perspective view of the exemplary parent roll transporter of FIG. 14 where the parent roll transporter is engaged with the conveyer and the first and second core plugs are ready for engagement with a vertically oriented core disposed upon a split conveyor departing from the up-ender;

FIG. 16 is a perspective view of an exemplary core plug suitable for use with the end effector of FIG. 1;

FIG. 17 is a plan view of the exemplary core plug of FIG. 16; and,

FIG. 18 is another plan view of the exemplary core plug of FIG. 16.

DETAILED DESCRIPTION

An exemplary schematic flow diagram of a through-drying process for making un-creped through-dried tissue sheets is shown in FIG. 3. It should be understood, however, that the present invention could also be used with the creping process for tissue webs. A head box 100 deposits an aqueous suspension of papermaking fibers onto an inner forming fabric 103 as it traverses a forming roll 104. An outer forming fabric 105 serves to contain the web 106 while it passes over the forming roll and sheds some of the water. The wet web 106 is then transferred from the inner forming fabric to a wet end transfer fabric 108 with the aid of a vacuum transfer shoe 109. This transfer is preferably carried out with the transfer fabric traveling at a slower speed than the forming fabric (rush transfer) to impart stretch into the final tissue sheet. The wet web is then transferred to the through-drying fabric 111 with the assistance of a vacuum transfer roll 112.

The through-drying fabric 111 carries the web over the through-dryer 113, which blows hot air through the web to dry it while preserving bulk. There can be more than one through-dryer in series (not shown), depending on the speed and the dryer capacity. The dried tissue sheet 115 is then transferred to a first dry end transfer fabric 116 with the aid of vacuum transfer roll 117.

The tissue sheet shortly after transfer is sandwiched between the first dry end transfer fabric 116 and the transfer belt 118 to positively control the sheet path. The air permeability of the transfer belt 118 is lower than that of the first dry end transfer fabric 116, causing the sheet to naturally adhere to the transfer belt. At the point of separation, the sheet follows the transfer belt due to vacuum action.

The transfer belt 118 passes over two support rolls 121 and 122 before returning to pick up the dried tissue sheet again. The sheet is transferred to the parent roll 125 at a point between the two support rolls 121, 122. The parent roll 125 is wound on a reel spool 126, which is driven by a center drive motor 127 acting on the shaft of the reel spool.

When the parent roll has reached its final predetermined diameter, the new reel spool is lowered into position against the incoming sheet at some point along the free span between the support rolls, generally relatively close to the first support roll 121, thereby avoiding a hard nip between the support roll and the reel spool. At the appropriate time, one or more air jets (not shown) serve to blow the sheet back toward the new reel spool in order to attach the sheet to the new reel spool As the sheet is transferred to the new reel spool, the sheet is broken and the parent roll 125 is kicked out to continue the winding process with a new reel spool.

Next, an up-ender (not shown) can then “up-end” each parent roll 125 downstream of the reel spool 126. Generally, an up-ender upends each parent roll 125 typically onto a conveyor (not shown) to position the longitudinal axis of each parent roll 125 vertically, i.e. orthogonal, to the plane of the winding process. In practice, rolls with small axial dimensions can be upended spontaneously with or without an up-ender, while those with larger axial dimensions can be, or due to their size, may be required to be, upended by an up-ender.

As shown in FIG. 4, the upended rolls 125 can be fed via a conveyor system towards a parent roll conveyor 150 from which they can be singly picked up by a parent roll transporter indicated as 1000. Generally parent roll transporter 1000 comprises a motivator having an end effector 1100 operatively, cooperatively, and pivotably connected thereto.

The end effector 1100 generally comprises a frame 1145 comprising opposed first and second collinear radial members 1150 and 1155 and parallel longitudinal members 1160 and 1165 secured together orthogonally thereto. In a preferred embodiment, first and second radial members 1150 and 1155 and longitudinal member 1160 can be secured together as by welding. In another preferred embodiment, longitudinal member 1165 can be extensibly connected to second radial member 1155 so that longitudinal member 1165 is provided with an adjustable displacement, H, relative to longitudinal axis 1140 (also referred to herein as axis of rotation 1140).

End effector 1100 is generally provided with the ability to rotate about axis of rotation 1140 in a radial direction, R, relative to motivator 1200. Having end effector 1100 rotate about axis of rotation 1140 can provide with the ability to orient radial members 1150 and 1155 and longitudinal members 1160 and 1165 into virtually any opposed relationship for the cooperative placement of radial members 1150 and 1155 and longitudinal members 1160 and 1165 relative to parent roll 125 and/or core 175. An end effector 1100 with the ability to rotate about axis of rotation 1140 can provide with the ability to orient parent roll 125 from a first position to any desired second orientation relative to the axis of rotation 1140. Further, providing the second radial member 1155 with an adjustable displacement, H, relative to longitudinal axis 1140 can facilitate the positioning of longitudinal member 1165 relative to parent roll 125 to accommodate a parent roll 125 having any longitudinal length. The desired adjustable displacement, H, can be provided by any device understood by one of skill in the art for providing such adjustment. This can include linear actuators, pneumatic actuators, hydraulic actuators, mechanical actuators (such as chain drives, gear drives, rack-and-pinion drives), combinations thereof, and the like.

Additionally, the overall end effector 1100 can be raised and lowered by a height displacement, h, relative to motivator 1200 to accommodate the arrival height of an in-coming parent roll 125 as well as the required or desired disposal height of a parent roll to be discharged from parent roll transporter 1000. The desired adjustable displacement, h, can be provided by any device understood by one of skill in the art for providing such adjustment. This can include linear actuators, pneumatic actuators, hydraulic actuators, mechanical actuators (such as chain drives, gear drives, rack-and-pinion drives), combinations thereof, and the like.

As shown in FIGS. 4-8, the distal ends of parallel longitudinal members 1160 and 1165 are provided with a first core plug 1130 and second core plug 1135 respectively. It is envisioned that first core plug 1130 and second core plug 1135 are separately engageable and/or mutually cooperatively engageable with a respective end of core 175 of parent roll 125 and displaceable within the respective end of core 175. First core plug 1130 can be fixably attached to the distal end of longitudinal member 1165 where such attachment of second core plug 1135 is being made rigid by welding to longitudinal member 1165, for example. Longitudinal member 1165 can be provided with any length desired for example as longitudinal member 1165A. The length of longitudinal member 1165 may be advantageously lengthened as provided by longitudinal member 1165A in order to provide control of the web material disposed about the core 175 of parent roll 125 if the web material may have a low coefficient of friction or some other attribute that may enhance the ability of one layer, or layers, of parent roll 125 to slidably translate relative to a succeeding layer, or layers, of parent roll 125. Further, second core plug 1135 can be provided with any length desired to effect the desired insertion engagement into the respective end of core 175 cooperatively associated thereto in order to provide the required support, lifting ability, and the like for the parent roll 125. For example, if parent roll 125 is heavy or is fairly long (i.e., parent roll 125 has a relatively long longitudinal axis, for example, a parent roll of paper used for the manufacture of tissue and towel products), then it may be appropriate to provide second core plug 1135 with a fairly long length as opposed to a parent roll 125 having a relatively light weight or short length (i.e., parent roll 125 has a relatively short longitudinal axis, for example, a parent roll of web material used for the manufacture of diaper products).

Alternatively, if space constraints require minimizing (or even restraining) the extension of radial member 1155 relative to longitudinal axis 1140, one of skill in the art may desire to provide second core plug 1135 in a manner that permits the extensible displacement of second core plug 1135 relative to the distal end of parallel longitudinal member 1165. In a first position, second core plug 1135 can be positioned to have a profile that is flush with the surface of parallel longitudinal member 1165 in order to present second core plug 1135 to the respective end of parent roll 125 and core 175. Upon the positioning of second core plug 1135 at the respective end of parent roll 125 and core 175, second core plug 1135 can then be extended relative to the distal end of parallel longitudinal member 1165 into core 175 as may be required. In any regard, one of skill in the art will readily recognize the benefits associated with the flexibility of the above-described arrangements possible for the second core plug for cooperative association and engagement with the core 175 of parent roll 125.

As shown in FIGS. 4-8, disposed across from second core plug 1135 and parallel longitudinal member 1165 is a first core plug 1130 disposed upon the distal end of parallel longitudinal member 1160. As presented in FIG. 4, first core plug 1130 can be disposed within platform 1110. In this manner, both the first core plug can engage the corresponding end of core 175 of parent roll 125 and the corresponding end of parent roll 125 can be placed into contacting and supporting engagement with platform 1110. Such contacting and supporting engagement can provide additional columnar stability to parent roll 125 when platform 1110 is disposed under parent roll 125 so that core 175 of parent roll 125 is disposed orthogonal to the surface of platform 1110. Upon the positioning of the respective end of parent roll 125 and core 175 proximate to first core plug 1130, first core plug 1130 can then be extended orthogonal to, and relative to, the distal end of parallel longitudinal member 1160 and the surface of platform 1110 as shown in FIG. 5 into core 175 as may be required. In any regard, one of skill in the art will readily recognize the benefits associated with the flexibility of the above-described arrangements possible for the first core plug 1130 for cooperative association and engagement with the core 175 of parent roll 125 represented in FIGS. 6-8.

Without desiring to be bound by theory, it is believed that an end effector 1100 having the spaced-apart core plugs (i.e., first core plug 1130 and second core plug 1135 discussed supra) helps maintain any caliper that may have been built into the product being produced for the parent roll because the spaced-apart core plugs of end effector 1100 do not actually contact the surface of the web material disposed about the core 175 of parent roll 125. This is quite the opposite of the prior art compressive-type parent roll clamps. In this manner, it is reasonably believed that a round parent roll handled by the end effector 1100 of the present disclosure will produce a finally wound consumer products having consistent desired physical characteristics.

As discussed supra, it is believed that a compressive-type clamp used for the conventional pick-up of a parent roll of wound web material effectively removes any caliper that may have been built into the product being produced for the parent roll. This lost caliper cannot be recovered to any large degree due to the early stage of the life of the web material that is being so compressed. This lost and unrecoverable caliper can have a deleterious effect on the finally converted web material because the desired target values of the chosen parameters will be out of range even before the converting process has begun. Net—this clearly undesirable effect on the end product can be noticed by an end user of the product. Clearly, the parent roll transporter 1000 having the end effector 1100 of the present disclosure eliminates and clearly remedies this awful and detrimental side-effect.

Additionally, the parent roll transporter 1000 having the end effector 1100 of the present disclosure can eliminate any eccentricity developed by the parent roll due to the handling caused by previous parent roll transport mechanisms. Eccentricity is a parameter associated with every conic section. It can be thought of as a measure of how much the conic section deviates from being circular. For example, a desirable parent roll that causes minimal disruptions during a converting operation will be perfectly cylindrical and have a circular cross-section where the eccentricity is zero (or nearly zero). Previous roll transport devices that effectively compressed the parent roll introduce a degree of eccentricity to the cross-section of the parent roll—i.e., the eccentricity is greater than zero. For purposes of this disclosure, a parent roll having any cross-sectional shape other than a circle has an eccentricity of greater than zero. Thus, a parent roll having, for example, a cross-sectional shape resembling a flat tire, a figure-eight, a polygon, or any other non-circular cross section, has an eccentricity of greater than zero. In certain cases, the eccentricity can be significantly greater than zero.

Thus, a goal of the present disclosure is to provide a process that can provide for an increase in the convertability of a convolutely wound parent roll by reducing the eccentricity in the parent roll caused by parent roll transport mechanisms (such as the exemplary prior art paper roll handling clamp shown in FIGS. 1-2). In other words the parent roll is produced by a papermaking process and has a first eccentricity (preferably about zero) and is transported to a converting process by a parent roll transporter 1000 that effectively maintains its eccentricity. Alternatively, the process can also be expressed as method to improve the convertibility of parent rolls by using a parent roll transport process that transports a parent roll having a first eccentricity from a papermaking process to a converting process at a second eccentricity, where the first and second eccentricities are about the same value. Still further, the process relationship can be expressed in terms of a comparison of the eccentricity of a parent roll that has been transported by a previous parent roll transport mechanisms and by a parent roll conveyor 150 where the previous parent roll transport mechanisms provides the parent roll 125 to a converting operation at a first eccentricity and the presently described parent roll conveyor 150 provides the parent roll 125 to a converting operation at a second eccentricity where the second eccentricity is less than the first eccentricity.

Platform 1110 can be provided in a plurality of envisionable formats. In a first embodiment, platform 1110 can be provided as a conveyor comprising at least one conveyor belt 1170. Thus, as shown in FIG. 4, a parent roll 125 disposed upon parent roll conveyor 150 can be continuously conveyed from a first position external to parent roll transporter 1000 and end effector 1100 and into contacting engagement with the at least one conveyor belt 1170 of platform 1110. It is envisioned that each of the at least one conveyor belts 1170 of platform 1110 can rotate about and be supported by a plurality of rollers 1120. Further platform 1110 can be provided with the ability to translate rotationally, r, about an axis formed by first core plug 1130 and second core plug 1135 in order to present the parent roll 125 at any orientation relative to parent roll transporter 1000. This can be beneficial by, for example, facilitating the ability of an end-user of the parent roll transporter 1000 to place the parent roll 125 disposed upon platform 1110 at any location relative to parent roll transporter 1000 desired without the need to move and/or reposition parent roll transporter 1000.

As parent roll 125 assumes contacting engagement with the at least one conveyor belt 1170 upon exiting contacting engagement with parent roll conveyor 150, the at least one conveyor belt 1170 can transport and position the parent roll 125 into a region proximate to the centroid of platform 1110 so that the core 175 is disposed coaxially relative to first core plug 1130. This positioning will then facilitate the insertion of first core plug 1130 into the corresponding end of core 175 as required.

Additionally, platform 1110 can be provided with at least one secondary conveyor belt 1175. Thus, as shown in FIG. 4, a parent roll 125 disposed upon parent roll conveyor 150 can be continuously conveyed from a first position external to parent roll transporter 1000 and end effector 1100 and into contacting engagement with the at least one conveyor belt 1170 and the at least one secondary conveyor belt 1175 of platform 1110. It is envisioned that each of the at least one secondary conveyor belts 1175 can rotate about and be supported by a plurality of rollers 1120. Secondary conveyor belts 1175 can assist with the ability to present the parent roll 125 at any orientation relative to parent roll transporter 1000. This can be beneficial by, for example, providing motive force to the portion of the parent roll disposed within the region disposed between adjacent conveyor belts forming the at least one conveyor belt 1170. This can reduce the overall drag experienced by the parent roll 120 in the region disposed between adjacent conveyor belts thus reducing any observed surface deformities of parent roll 125.

Alternative, as shown in FIG. 5, the region disposed between adjacent conveyor belts forming the at least one conveyor belt 1170 can be provided as a trough 1175′. This can eliminate the need for any additional mechanical needs required by the positioning of any secondary conveyor belts 1175 in the region disposed between adjacent conveyor belts forming the at least one conveyor belt 1170. This may be suitable if the parent roll 125 has sufficiaent roll integrity and physical characteristics that do not require complete support of the end of the parent roll 125 disposed upon platform 1110.

The system shown in FIGS. 4-8 can facilitate the transport of parent rolls 125 to locations distal from the papermaking operation and/or the dry end of a paper machine. A parent roll 125 provided in contacting engagement with platform 1110 and/or first core plug 1130 and second core plug 1135 can be conveyed to a location for storage of the parent roll 125 and then disengaged from any of first core plug 1130 and second core plug 1135 and conveyed off platform 1110 by the at least one conveyor belt 1170. One of skill in the art will recognize the viability of such a unique core transport system.

Alternatively, it may be advantageous to transport a parent roll 125 from the dry end of a papermaking process directly to a parent roll converting operation as discussed supra. To satisfy this need, one of skill in the art will recognize that parent roll transporter 1000 can provide the end effector 1100 cooperatively attached thereto can effectively rotate, R, parent roll 125 about the axis of rotation 1140. As shown in FIGS. 9 and 10, the longitudinal axis of parent roll 125 can be changed from a substantially vertical orientation as shown in FIG. 8 through the axis of rotation 1140 into a substantially horizontal orientation as shown in FIGS. 9-10.

Thus, in practice, a parent roll 125 disposed upon parent roll conveyor 150 can be continuously conveyed from a first position external to parent roll transporter 1000 and end effector 1100 and into contacting engagement with the at least one conveyor belt 1170 of platform 1110. As parent roll 125 assumes contacting engagement with the at least one conveyor belt 1170 upon exiting contacting engagement with parent roll conveyor 150, the at least one conveyor belt 1170 can transport and position the parent roll 125 into a region proximate to the centroid of platform 1110 so that the core 175 is disposed coaxially relative to first core plug 1130. This positioning will then facilitate the insertion of first core plug 1130 and second core plug 1135 into the corresponding end of core 175 as required. The parent roll transporter can then rotate, R, end effector 1100 about the axis of rotation 1140 as required. The rotated parent roll 125 can then be disposed as required by the converting process. As the parent roll is positioned for the converting process desired, first core plug 1130 and second core plug 1135 can then be retracted (e.g., withdrawn) from inserted engagement within core 175 thereby removing contacting engagement of parent roll 125 from end effector 1100. The disengaged roll can then be processed as required.

Also as shown in FIG. 10, the parent roll transporter can then position the end effector 1100 laterally, z, relative to motivator 1200 as required. Any lateral, z, movement can be used assist in aligning the parent roll 125 with the converting equipment. For example, a degree of lateral movement, z, may be required in order to align and dispose the parent roll 125 upon an unwind stand used by the converting equipment unwind. It is believed that the control of such lateral movement, z, can be provided by the motivator or by any device understood by one of skill in the art for providing such adjustment. This can include linear actuators, pneumatic actuators, hydraulic actuators, mechanical actuators (such as chain drives, gear drives, rack-and-pinion drives), combinations thereof, and the like.

Alternatively, the parent roll transporter 1000 can be destined to transport the cooperatively engaged parent roll 125 to a storage area with the parent roll core 175 disposed thereon. Upon reaching the storage area, the parent roll 125 while disposed upon platform 1110 can be disassociated from the first and second core plugs. Platform 1110 can then be operatively disconnected from either end effector 1100 or parent roll transporter 1000 to provide a storage means for the upright storage of parent roll 125. This can result in a combined parent roll 125/platform 1110 assembly as shown in FIG. 8A. A first core plug can be positioned within the surface of platform 1110 and either operably attached and permanently associated with platform 1110. Thus, the platform 1110 and the first core plug associated thereto would operably disconnect from end effector 1100. Alternatively, first core plug 1130 can be operably attached and temporarily associated thereto. Thus, the platform 1110 would operably disconnect from end effector 1100 while the first core plug would be removed from cooperative engagement with platform 1110 and remain in operative and connecting engagement with end effector 1100. IN other words, platform 1110 can be disassociatively disengageable and/or cooperatively engageable with end effector 1100 and/or first core plug 1130 as may be required by the end user. This can result in platform 1110 being disassociatively disengageable and/or cooperatively engageable relative to first core plug 1130 and end effector 1100 or platform 1110 and first core plug 1130 being disassociatively disengageable and/or cooperatively engageable relative to end effector 1100.

Alternatively, if the parent roll 125 is to be picked up directly from the dry end of a paper machine and taken directly to a parent roll 125 storage facility, the parent roll transporter 1000A can be provided with a motivator 1200 operatively connected to end effector 1100 having a platform 1110A in the form of a pallet as shown in FIG. 11. Here, the parent roll transporter 1000A can approach the dry-end of the paper machine directly. The parent roll 125 is typically positioned so that the core 175 of the parent roll 125 is horizontally oriented so that the web material produced by the papermaking equipment is wound about the core 175 is co-planar and parallel to the longitudinal axis of the parent roll 125 and core 175.

Parent roll transporter 1000A can approach parent roll 125 disposed in the reel-up section of the dry end of the papermaking equipment (including a reel spool) so that the end effector 1100A presents the first core plug (not shown) and second core plug 1135 to cooperatively and insertingly engage the horizontally oriented core 175 of the wound parent roll 125. As shown, first core plug (not shown) is preferably fixably attached to the distal end of a longitudinal member (not shown) and second core plug 1135 is rigidly affixed to longitudinal member 1165. The first and second core plugs are preferably provided with any length desired to effect the desired insertion engagement into the respective end of core 175 cooperatively associated thereto in order to provide the required support, lifting ability, and the like for the parent roll 125.

Parent roll transporter 1000A can then transport the cooperatively engaged parent roll 125 to the storage area with the parent roll core 175 oriented in either a horizontal or vertical orientation. Upon reaching the storage area, the parent roll 125 while disposed upon platform 1110A can be disassociated from the first and second core plugs. Platform 1110A can then be operatively disconnected from either end effector 1100A or parent roll transporter 1000 to provide a storage means for the upright storage of parent roll 125. This can result in a combined parent roll 125/platform 1110A assembly as shown in FIG. 13. A first core plug can be positioned within the surface of platform 1110A and either operably attached and permanently associated with platform 1110A. Thus, the platform 1110A and the first core plug associated thereto would operably disconnect from end effector 1100. Alternatively, a first core plug can be operably attached and temporarily associated thereto. Thus, the platform 1110A would operably disconnect from platform 1110A while the first core plug would be removed from cooperative engagement with platform 1110A and remain in operative and connecting engagement with end effector 1100A.

As represented by the alternative embodiment of FIG. 14, the parent roll transporter 1000B can approach parent roll 125 disposed in the reel-up section of the dry end of the papermaking equipment so that the end effector 1100B presents the first core plug (not shown) and second core plug 1135 to cooperatively and insertingly engage the horizontally oriented core 175 of the wound parent roll 125. As shown, first core plug (not shown) is preferably fixably attached to the distal end of a longitudinal member (not shown) and second core plug 1135 is rigidly affixed to longitudinal member 1165. The first and second core plugs are preferably provided with any length desired to effect the desired insertion engagement into the respective end of core 175 cooperatively associated thereto in order to provide the required support, lifting ability, and the like for the parent roll 125. In this embodiment, end effector 1100B is not provided with a platform in cooperative engagement with the first core plug (not shown). Net—there is no need for the additional infrastructure required to operatively connect a platform relative to end effector 1100B.

Parent roll transporter 1000B can then transport the cooperatively engaged parent roll 125 directly to a converting operation with the parent roll core 175 oriented in either a horizontal or vertical orientation. Upon reaching the converting operation, the parent roll 125 while disposed between the first and second core plugs can be disassociated from the first and second core plugs. This can result in a parent roll 125 being more directly associated with the converting operation as parent roll 125 formation is completed in the papermaking process. One of skill in the art will recognize that this embodiment of parent roll transporter 1000B will facilitate the connection of the parent roll formed in the papermaking process with the longitudinal axis of the parent roll 125 oriented generally horizontally to the parent roll transporter 1000B without the need for re-orientation of the parent roll 125 as is normally done in papermaking processes. Such reorientation is typically associated with the use of the roll-clamp devices referenced supra. In other words, the up-ender, typically and routinely used in papermaking for re-orienting parent rolls can be eliminated from the process thereby simplifying the papermaking dry end process as well as reducing the costs associated with a now unnecessary up-ender.

Additionally, as shown in FIG. 15-15A, the parent roll transporter 1000B can approach an upended parent roll 125 disposed upon a conveyor (e.g., the parent roll conveyor 150 as shown in FIG. 4). Here, the end effector 1100B presents the first core plug 1130 and second core plug 1135 to cooperatively and insertingly engage the vertically oriented core 175 of the wound parent roll 125 through a slot 155 disposed relative to the terminus (or the ‘turn-around point) of conveyor 150. As shown, conveyor 150 could be provided as a pair of parallel and co-planar conveyors positioned in a spaced-apart manner to provide slot 155 disposed therebetween.

Here, the first core plug 1130 is preferably fixably attached to the distal end of a longitudinal member 1160 and second core plug 1135 is rigidly affixed to longitudinal member 1165. The first and second core plugs are preferably provided with any length desired to effect the desired insertion engagement into the respective end of core 175 cooperatively associated thereto in order to provide the required support, lifting ability, and the like for the parent roll 125. In this embodiment, end effector 1100B is not provided with a platform in cooperative engagement with the first core plug 1130. Net—there is no need for the additional infrastructure required to operatively connect a platform relative to end effector 1100B. The end effector 1100B can effectively engage the opposed ends of core 175 of parent roll 125 and immediately transfer the parent roll from the dry end of the papermaking process to a converting process with or without re-orientation of the core 175 relative to the horizon.

FIGS. 16-18 provide different perspective, planar, and sectional views of a suitable core plug 1130, 1135 such as that shown in FIGS. 15-15A. By non-limiting example, core plug 1130, 1135 is provided with a plurality of elongate mandrel arms 1310 disposed radially about the longitudinal axis 1340 of mandrel 1300 and extending from mandrel shaft 1320. Each mandrel arm 1310 is provided with at least one expansion element 1330, and in most cases a plurality of expansion elements 1330 disposed upon the outer surface thereof. In principle, mandrel 1300 is inserted into the hollow core area of a convolutley wound material. The associated expansion elements 1330 associated with each mandrel arm 1310 are then expanded radially away from longitudinal axis 1340. The outward expansion of the expansion elements 1310 is limited by the diameter of the hollow core area of the convolutely wound web material. Upon proper expansion of the expansion elements 1310 against the hollow core of the convolutely wound web material, a compression fit is realized that effectively provides the end effector 1230 having the convolutely wound web material attached thereto to freely move about and position the roll of convolutely wound web material be positioned as may be required.

As depicted, mandrel 1300 is provided with three mandrel arms 1310 arranged triangularly about longitudinal axis 1340. Naturally, one of skill in the art could provide a mandrel 1300 with any number of mandrel arms 1310 disposed as required about longitudinal axis 1340. For example, one of skill in the art could provide only two mandrel arms 1310 or even four mandrel arms 1310.

The parent roll transporter 1000 of the present disclosure, as discussed supra, can be operatively connected or associated with a motivator 1200. One of skill in the art will appreciate that motivator 1200 could be provided as an automatic guided vehicle (AGV), as a more traditional forklift, or with some other form of robotic systems. In any regard, the motivator 1200 is used to move the end effector 1100, with or without a parent roll 125 cooperatively engaged thereto, between various points along a desired route in a manufacturing process.

The parent roll transporter 1000 of the present disclosure is especially suitable with a motivator 1200 provided as an AGV. A plurality of AGVs can function as a system having a number of battery powered, wheeled, operatorless vehicles (i.e., AGV) which are automatically guided along the floor in a warehouse or other commercial or industrial site, where guide path wires are embedded in the floor, and under the control of on-board computers. Each AGV can be provided with accurate and reliable guidance and routing where a controller may be operated either on-board or remotely from the vehicle.

It is the purpose of the motivator 1200 to move material between various points along a route on vehicles which can be programmed to follow a preset choice of routes and to carry out various operations along the route, such as stops and turns. Most systems which have been proposed use induction guidance where the guide path is defined by a wire embedded in the floor. An AC current, fed through the wire, generates an electromagnetic field which is detected by coils on the vehicle which track the wire. Two coils are used in most cases which provide a differential current when the vehicle deviates from the wire which is used to control the steering of the vehicle so as to return it to its proper track. The guide path is usually in the form of a loop. By using two or more different frequencies of the AC current for different legs of the route, complex routes can be built up. Route selection is, in some systems, controlled by a computer on board each vehicle which programs the vehicle to follow a preset route. Typically, permanent magnets or electromagnetic loops and floor controllers installed in the floor divide the route into sections. In a typical installation, the program control computer instructs the vehicle to count its way along the route and to respond to different frequencies so as to follow different legs of the route.

An exemplary AGV suitable for use as a motivator 1200 can travel along a track formed on a floor by a white line or aluminum foil while detecting the track by means of an optical track sensor. In this type of conventional vehicle having, for example, three wheels, one front wheel and a pair of rear wheels, the front wheel can be driven through a connection to a driving system and can be automatically steered by a steering system while the rear wheels are freely rotatable but incapable of being driven by any driving system being steered.

Another exemplary AGV suitable for use as a motivator 1200 is a four-wheel vehicle having front and rear wheels and on the opposite sides of a center axis having left and right wheels each of which is provided with a driving motor. In this example, all wheels are set in the forward direction and the left and right wheels are driven by the driving motors so as to perform the ordinary travelling operation of the vehicle. The vehicle moves straight by equalizing the speeds of rotation of the left and right wheels and turns left or right by changing the speed ratio therebetween. At least the direction of the front wheels among the front and rear wheels can be freely changed so as to follow the motion caused when the left and right wheels are steered by changing the speed ratio therebetween. If the front and rear wheels are rotated in the reverse directions at the same rotational speed while the front and rear wheels are being fixed such as to be perpendicular to the direction of the front and rear of the vehicle body, the body of the vehicle can be turned about the point of intersection of the lines which connect the front wheel to the rear wheel and the left wheel to the right wheel.

Alternatively, the parent roll transporter 1000 of the present disclosure is also suitable with a motivator 1200 provided as a forklift truck. An exemplary forklift truck could comprise a forklift truck known in the art for the moving of large and/or heavy objects such as articles commonly found in warehouses, manufacturing facilities, and/or the like.

An exemplary forklift would comprise an undercarriage with an operator cabin including an operator seat unit pivotally supported therein. A load lifting unit including a lifting frame and a lifting fork is mounted to the front end of the undercarriage. Two front wheels and two steerable rear wheels and further a rear box structure with a lid can also be mounted to the under carriage. The forklift truck can be operated by an electric motor, natural gas, propane, gasoline, diesel fuel, and the like. The forklift can be energized by a battery, which can be disposed in a box structure that also serves as a counterweight for loads lifted by the load lifting unit.

In any regard, the motivator 1200 is operatively and cooperatively engaged with end effector 1100 to form parent roll transporter 1000. Such cooperative and operative engagement can be provided by a mechanical, electrical, and/or hydraulic latching mechanisms. It may be preferred to use pneumatic connections since pneumatic systems due to the ease of installation, maintenance, low cost, and light weight. Hydraulic systems may be preferred if the parent roll transporter 1000 will necessarily be used to lift and/or move large and/or heavy parent rolls 125. Electric systems can prove for more quiet connections.

Suitable means for attaching end effector 1100 to motivator 1200 can be provided by a mounting plate attached at a position suitable for cooperative engagement between end effector 1100 and motivator 1200. The mounting plate can contain threaded or clearance holes arranged in a pattern for suitable attachment with a coupling device. An adapter plate can be used for interconnection with a common lock-in position for pick-up by the motivator 1200. The coupling device may also contain the power source for the end effector 1100 and may automatically connect the power when the motivator 1200 picks up and connects to the end effector 1100. Alternatively, the end effector 1100 may have a power connection permanently connected thereto and the motivator 1200 simply picks up the end effect 1100 by connecting to an appropriate adapter plate with common lock-in points.

As would be recognized by one of skill in the art, any of the parent roll transporter 1000, motivator 1200, end effector 1100, and/or parent roll 125 can be provided with an RFID device, such as a tag, in order to assist with the transport, storage, connection, placement, location, etc. of any of parent roll 125 or platform 1110 or motivator 1200, or end effector 1100 or parent roll transporter 1000 relative to any of the initial pick-up of the parent roll 125 or storage or transport of parent roll 125 relative to the papermaking, storage, and/or parent roll converting processes.

Such an RFID system can assist with and is known and understood by those skilled in the art, and a detailed explanation thereof is not necessary for purposes of describing the method and system according to the present invention. As discussed above, RFID or other smart tag technology is finding increasing uses in material handling and processing environments, particularly in warehouse or other storage facilities wherein articles are stored and moved in the process of converting raw materials to finished products. RFID tags containing any manner of information related to the articles may be attached directly to the articles (such as parent roll 125), or associated with pallets, racks, bins, or any type of article packaging.

RFID tags of any known type may be used, including active RFID tags, passive RFID tags, and semi-passive RFID tags. Active RFID tags are battery-powered devices that transmit a signal to a reader and typically have long ranges such as 100 feet or more. Passive RFID tags are not battery powered but draw energy from electromagnetic waves from an RFID reader. Passive RFID tags often have a range of about 10 feet or less. Semi-passive RFID tags employ a battery to run the circuitry of a chip but rely on electromagnetic waves from a reader to power the transmitted signal.

Generally, passive smart tags consist of an integrated circuit, other semiconductors such as diodes, a coiled, etched, or stamped antenna, passive components such as resistors and capacitors, and a substrate on which the components are mounted or embedded. A protective covering is typically used to encapsulate and seal the substrate. Inductive or passive smart tags are commercially available from a number of vendors, including Motorola®. A description of certain types of these devices may be found in U.S. Pat. No. 6,259,367 B1. Another commercial source of suitable smart tags is Alien Technology Corporation of Morgan Hill, Calif., under the technology name FSA (Fluidic Self-Assembly). With the FSA process, tiny semi-conductor devices are assembled into rolls of flexible plastic. The resulting “smart” substrate can be attached or embedded in a variety of surfaces. The smart tag technology under development at the Auto-ID Center at Massachusetts Institute of Technology (Cambridge, Mass.) can also be used within the scope of the present invention.

High frequency bands can be used in RFID technology, such as bands between 300 MHz and 10 GHz. SCS Corporation (Rancho Bernardo, Calif.), for example, markets smart tag technology at 2.45 GHz. Ultra-wide band technology can also be adapted for RFID systems.

Exemplary RFID tag manufacturers include Matrics, Alien Technology, Philips Semiconductor, and Texas Instruments. Manufacturing may be done by robotic techniques (e.g., “flip-chip”/“pick and place” techniques), fluidic self-assembly (FSA), the Philips “I-connect” method or the Philips “vibratory assembly” method, or other known processes. Exemplary RFID reader manufacturers include Intemec Technologies, Symbol Technologies, Matrics, AWID (e.g., their multi-protocol reader operate at various frequencies), and others. Software systems to support RFID systems are provided by IBM Global Services (which has acquired PriceWaterhouseCoopers), Texas Instruments, Manhattan Associates (particularly for integrated supply chain executions), SAP, and others. Printed RFID labels may be made using equipment from Zebra Technologies and other vendors.

RFID tags include an antenna that may be made by any known method, including metal deposition, printing of conductive inks, etc. By way of example, the RFID tags may employ conductive ink technology of RCD Technologies (Bethlehem, Pa.). Antennae may be printed using any known format, and may, for example, comprise double-sided, interconnected coils. Any known frequency may be used, such as 100 kHz or 125 kHz (“low frequency”), 13.56 MHz (“high frequency”), 860 930 MHz such as 900 MHz or 915 MHz (“ultra high frequency” or UHF), and 2.45 GHz or 5.8 GHz (microwave frequency), or other known frequencies. The type of antenna (i.e., inductive or capacitive) is generally a function of the operating range of the system.

The RFID system may follow the systems disclosed by the MIT Auto-ID Center, including the use of an electronic product code (EPC); an EPCIS system (Electronic Product Code Information Services from EPCglobal) to manage the codes being read with a distributed architecture and processes such as data smoothing, reader coordination, data forwarding, data storage, and task management; and Object Name Service (ONS) for matching EPC information to item information, typically using a domain name service (DNS) to route computers to Internet sites; and Physical Markup Language (PML) to describe information about a product.

Examples

-   A. A process for improving the convertability of parent rolls of     convolutely wound web materials, the process comprising the steps     of:     -   a) producing a web material with a paper machine;     -   b) forming a parent roll of said web material by convolutely         winding said web material about a core to form said parent roll;     -   c) operatively engaging an end effector having a first core plug         and a second core plug operatively connected thereto with said         core of said parent roll, said first core plug engaging a first         end of said core and said second core plug operatively engaging         a second end of said core, said second end being distal from         said first end, said end effector being operatively connected to         a motivator to form a parent roll transport device;     -   d) transporting said parent roll with said parent roll transport         device to a parent roll converting apparatus;     -   e) operatively disposing said parent roll in said converting         apparatus; and,     -   f) converting said parent roll. -   B. The process of A wherein said step of forming a parent roll of     said web material by convolutely winding said web material about a     core to form said parent roll further comprises the step of forming     said parent roll of said web material by convolutely winding said     web material about said core to form said parent roll having a first     eccentricity. -   C. The process of any of A through B wherein said step of     operatively disposing said parent roll in said converting apparatus     further comprises the step of operatively disposing said parent roll     in said converting apparatus with a second eccentricity, said first     and second eccentricities being equal. -   D. The process of any of A through C further comprising the step of     cooperatively engaging a platform with said second core plug and     said end effector, a first end of said parent roll being engaged     with a surface of said platform when said first core plug is engaged     with said first end of said core and said second core plug is     engaging with said second end of said core. -   E. The process of D further comprising the step of disengaging said     platform from said end effector after said parent roll is engaged     with said surface of said platform and after said first core plug     and said second core plug are removed from said core. -   F. The process of D further comprising the step of providing said     platform with a conveyor, said conveyor traversing about said     surface of said platform, said conveyor conveying said parent roll     from a first position to a second position providing cooperative     alignment of said core of said parent roll with said first core plug     and said second core plug. -   G. The process of D further comprising the step of disengaging said     platform and said second core plug from said end effector after said     parent roll is engaged with said surface of said platform and after     said first core plug is removed from said core, said second core     plug remaining operatively engaged with said second end of said     core. -   H. The process of D wherein said step of engaging said first end of     said parent roll with said surface of said platform further     comprises the steps of engaging said first end of said parent roll     having a first eccentricity with said surface of said platform and     operatively disposing said parent roll having a second eccentricity     in said converting apparatus, said first and second eccentricities     being equal. -   I. The process of D wherein said step d) further comprises the step     of directly transporting said parent roll from said paper machine to     said converting apparatus. -   J. The process of D further comprising the steps of, after said step     c), disengaging said platform from said end effector after said     parent roll is engaged with said surface of said platform and after     said first core plug and said second core plug are removed from said     core, and subsequently re-engaging said platform with said end     effector. -   K. The process of any of A through J wherein said step d) further     comprises the step of directly transporting said parent roll from     said paper machine to said converting apparatus. -   L. The process of any of A through K further comprising the step of,     after said step c) rotationally reorienting said core from a first     position to a second position with said end effector. -   M. A process for improving the convertability of parent rolls of     convolutely wound web materials, the process comprising the steps     of:     -   a) producing a web material with a paper machine;     -   b) forming a parent roll of said web material by convolutely         winding said web material about a core to form said parent roll;     -   c) operatively engaging an end effector having a first core         plug, a second core plug, and a platform disposed about said         second core plug operatively connected thereto with said core of         said parent roll, said first core plug engaging a first end of         said core, said second core plug operatively engaging a second         end of said core, and a first end of said parent roll being         engaged with a surface of said platform when said first core         plug is engaged with said first end of said core and said second         core plug is engaging with said second end of said core, said         second end being distal from said first end, said end effector         being operatively connected to a motivator to form a parent roll         transport device;     -   d) transporting said parent roll with said parent roll transport         device to a parent roll converting apparatus;     -   e) operatively disposing said parent roll in said converting         apparatus; and,     -   f) converting said parent roll. -   N. The process of M further comprising the step of providing said     platform with a conveyor, said conveyor traversing about said     surface of said platform, said conveyor conveying said parent roll     from a first position to a second position providing cooperative     alignment of said core of said parent roll with said first core plug     and said second core plug. -   O. The process of any of M through N further comprising the step of,     after said step c) rotationally reorienting said core from a first     position to a second position with said end effector. -   P. The process of any of M through O further comprises the steps of     during said step b), forming said parent roll of said web material     by convolutely winding said web material about said core to form     said parent roll having a first eccentricity and said step e)     further comprises the step of operatively disposing said parent roll     in said converting apparatus with a second eccentricity, said first     and second eccentricities being equal. -   Q. The process of any of M through P further comprising the steps of     after said step c), disengaging said platform from said end effector     after said first core plug and said second core plug are removed     from said core and subsequently re-engaging said platform with said     end effector. -   R. The process of any of M through R wherein said step d) further     comprises the step of directly transporting said parent roll from     said paper machine to said converting apparatus. -   S. The process of any of M through R further comprising the step of,     after said step c) rotationally reorienting said core from a first     position to a second position with said end effector. -   T. The process of any of M through S further comprising the steps     of:     -   g) forming a second parent roll of said web material;     -   h) operatively engaging said end effector with a core of said         second parent roll;     -   i) transporting said second parent roll with said parent roll         transport device to said parent roll converting apparatus;     -   j) operatively disposing said second parent roll in said         converting apparatus; and, converting said second parent roll.

The dimensions and/or values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension and/or value is intended to mean both the recited dimension and/or value and a functionally equivalent range surrounding that dimension and/or value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention. 

What is claimed is:
 1. A process for improving the convertability of parent rolls of convolutely wound web materials, the process comprising the steps of: a) producing a web material with a paper machine; b) forming a parent roll of said web material by convolutely winding said web material about a core to form said parent roll; c) operatively engaging an end effector having a first core plug and a second core plug operatively connected thereto with said core of said parent roll, said first core plug engaging a first end of said core and said second core plug operatively engaging a second end of said core, said second end being distal from said first end, said end effector being operatively connected to a motivator to form a parent roll transport device; d) transporting said parent roll with said parent roll transport device to a parent roll converting apparatus; e) operatively disposing said parent roll in said converting apparatus; and, f) converting said parent roll.
 2. The process of claim 1 wherein said step of forming a parent roll of said web material by convolutely winding said web material about a core to form said parent roll further comprises the step of forming said parent roll of said web material by convolutely winding said web material about said core to form said parent roll having a first eccentricity.
 3. The process of claim 2 wherein said step of operatively disposing said parent roll in said converting apparatus further comprises the step of operatively disposing said parent roll in said converting apparatus with a second eccentricity, said first and second eccentricities being equal.
 4. The process of claim 1 further comprising the step of cooperatively engaging a platform with said second core plug and said end effector, a first end of said parent roll being engaged with a surface of said platform when said first core plug is engaged with said first end of said core and said second core plug is engaging with said second end of said core.
 5. The process of claim 4 further comprising the step of disengaging said platform from said end effector after said parent roll is engaged with said surface of said platform and after said first core plug and said second core plug are removed from said core.
 6. The process of claim 4 further comprising the step of providing said platform with a conveyor, said conveyor traversing about said surface of said platform, said conveyor conveying said parent roll from a first position to a second position providing cooperative alignment of said core of said parent roll with said first core plug and said second core plug.
 7. The process of claim 4 further comprising the step of disengaging said platform and said second core plug from said end effector after said parent roll is engaged with said surface of said platform and after said first core plug is removed from said core, said second core plug remaining operatively engaged with said second end of said core.
 8. The process of claim 4 wherein said step of engaging said first end of said parent roll with said surface of said platform further comprises the steps of engaging said first end of said parent roll having a first eccentricity with said surface of said platform and operatively disposing said parent roll having a second eccentricity in said converting apparatus, said first and second eccentricities being equal.
 9. The process of claim 4 wherein said step d) further comprises the step of directly transporting said parent roll from said paper machine to said converting apparatus.
 10. The process of claim 4 further comprising the steps of, after said step c), disengaging said platform from said end effector after said parent roll is engaged with said surface of said platform and after said first core plug and said second core plug are removed from said core, and subsequently re-engaging said platform with said end effector.
 11. The process of claim 1 wherein said step d) further comprises the step of directly transporting said parent roll from said paper machine to said converting apparatus.
 12. The process of claim 1 further comprising the step of, after said step c) rotationally reorienting said core from a first position to a second position with said end effector.
 13. A process for improving the convertability of parent rolls of convolutely wound web materials, the process comprising the steps of: a) producing a web material with a paper machine; b) forming a parent roll of said web material by convolutely winding said web material about a core to form said parent roll; c) operatively engaging an end effector having a first core plug, a second core plug, and a platform disposed about said second core plug operatively connected thereto with said core of said parent roll, said first core plug engaging a first end of said core, said second core plug operatively engaging a second end of said core, and a first end of said parent roll being engaged with a surface of said platform when said first core plug is engaged with said first end of said core and said second core plug is engaging with said second end of said core, said second end being distal from said first end, said end effector being operatively connected to a motivator to form a parent roll transport device; d) transporting said parent roll with said parent roll transport device to a parent roll converting apparatus; e) operatively disposing said parent roll in said converting apparatus; and, f) converting said parent roll.
 14. The process of claim 13 further comprising the step of providing said platform with a conveyor, said conveyor traversing about said surface of said platform, said conveyor conveying said parent roll from a first position to a second position providing cooperative alignment of said core of said parent roll with said first core plug and said second core plug.
 15. The process of claim 13 further comprising the step of, after said step c) rotationally reorienting said core from a first position to a second position with said end effector.
 16. The process of claim 13 further comprises the steps of during said step b), forming said parent roll of said web material by convolutely winding said web material about said core to form said parent roll having a first eccentricity and said step e) further comprises the step of operatively disposing said parent roll in said converting apparatus with a second eccentricity, said first and second eccentricities being equal.
 17. The process of claim 13 further comprising the steps of after said step c), disengaging said platform from said end effector after said first core plug and said second core plug are removed from said core and subsequently re-engaging said platform with said end effector.
 18. The process of claim 13 wherein said step d) further comprises the step of directly transporting said parent roll from said paper machine to said converting apparatus.
 19. The process of claim 13 further comprising the step of, after said step c) rotationally reorienting said core from a first position to a second position with said end effector.
 20. The process of claim 13 further comprising the steps of: g) forming a second parent roll of said web material; h) operatively engaging said end effector with a core of said second parent roll; i) transporting said second parent roll with said parent roll transport device to said parent roll converting apparatus; j) operatively disposing said second parent roll in said converting apparatus; and, k) converting said second parent roll. 